With the progress of science and technology and the continuous development of manufacturing industry, warm forging technology, as an important forming process, plays a key role in manufacturing high-quality forgings. However, the traditional warm forging process may face some challenges in some cases, such as insufficient material fluidity, internal defects, etc. In order to solve these problems, ultrasonic assisted warm forging technology comes into being, which brings a new breakthrough for the improvement of forging performance.
Ultrasonic assisted warm forging technology is a new method to introduce ultrasonic vibration into warm forging process. Through the vibration effect of ultrasonic wave, the flow stress of the material can be effectively reduced, and the fluidity and filling performance of the material can be improved. At the same time, the high-frequency vibration of ultrasonic can also promote grain refinement, eliminate internal defects, and improve the mechanical properties of forgings.
Compared with traditional warm forging technology, ultrasonic assisted warm forging technology has the following advantages:
Improved material flow: Ultrasonic vibration can reduce the flow stress of the material, making it easier to fill the mold cavity and reduce the formation of defects.
Fine grain: ultrasonic high-frequency vibration can promote grain refinement, improve the strength and toughness of the material.
Improve forging quality: By eliminating internal defects and improving material structure, ultrasonic assisted warm forging technology can significantly improve the mechanical properties and quality stability of forgings.
Energy saving and emission reduction: Because ultrasonic assisted warm forging technology can reduce the deformation resistance of materials, reduce energy consumption and waste emissions, in line with the requirements of green manufacturing.
In order to verify the practical effect of ultrasonic assisted warm forging technology, we have carried out a series of practical case studies and analyses. Taking an automobile engine connecting rod as an example, ultrasonic assisted warm forging technology is used to produce it.
The practical results show that compared with the traditional warm forging process, the connecting rod produced by ultrasonic assisted warm forging technology has the following advantages:
Improved mechanical properties: By refining the grain and improving the material structure, the tensile strength, yield strength and impact toughness of the connecting rod have been significantly improved.
Improved dimensional accuracy: Ultrasonic vibration improves the fluidity and filling performance of the material, making the dimensional accuracy of the connecting rod significantly improved.
Internal quality improvement: By eliminating internal defects and reducing residual stress, the internal quality of the connecting rod has been significantly improved, reducing potential quality risks.
Production efficiency improvement: Because ultrasonic assisted warm forging technology can reduce the deformation resistance of materials, reduce mold wear and energy consumption, and improve production efficiency.
Although ultrasonic assisted warm forging technology has achieved remarkable results in improving forging performance, it also faces some challenges in practical application. For example, the equipment investment cost is high, and the process parameter optimization is difficult. To overcome these challenges and drive widespread adoption of the technology, here are some suggestions and prospects:
Reduce equipment costs: Reduce the manufacturing cost of ultrasonic equipment through technological innovation and large-scale production, making it more economical and popular.
In-depth study of process parameters: For different materials and part types, in-depth study of the optimal process parameters of ultrasonic assisted warm forging technology to improve production efficiency and forging quality.
Expand the application field: the ultrasonic assisted warm forging technology is promoted to other manufacturing fields such as aerospace, petrochemical, etc., to meet the needs of different industries for high-performance forgings.
Strengthen international cooperation and exchange: Cooperate and exchange with international advanced enterprises and research institutions to jointly promote the development and innovation of ultrasonic assisted warm forging technology.
As an innovative process method, ultrasonic assisted warm forging technology has shown great potential in improving forging performance. By improving material fluidity, refining grain and improving forging quality, this technology provides a new way for the high-quality development of manufacturing industry. Although there are still some challenges in the practice process, with the continuous progress of technology and the continuous expansion of application scenarios, it is believed that ultrasonic assisted warm forging technology will play a greater role in the future and make important contributions to the continuous innovation and development of the manufacturing industry.
